Toilet flapper

ABSTRACT

A system and method for controlling the flow of fluid through a discharge outlet. A flapper assembly moveable between an open position, at least one intermediate position, and a closed position. In the open position fluid is able to flow substantially unrestricted by the flapper assembly through the discharge outlet. In the closed position fluid is prevented from flowing through the discharge outlet. In the at least one intermediate position fluid is partially restricted, but not prevented, from flowing through the discharge outlet.

FIELD OF THE INVENTION

[0001] This invention relates to the field of fluid valves generallywith specific, but not exclusive, application to toilet flappers.

BACKGROUND OF THE INVENTION

[0002] Environmental practices such as water conservation are increasingin importance. The economic advantages of reducing water consumption arefurther driving this trend. In many jurisdictions, regulatory standardshave been implemented governing the amount of water that toilets andother water devices and appliances may utilize.

[0003] Such regulatory standards typically apply to newly installedtoilets. To achieve reduced water usage, newer toilets are oftenprovided with smaller toilet tanks and incorporate other designefficiencies. However, many existing, older toilets continue to uselarge volumes of water and are much less efficient than their newercounterparts. Techniques exist for reducing the storage capacity ofwater tanks of older toilets, such as by putting a brick in the tank.While such techniques do reduce some water consumption, inefficiencyremains.

[0004] Accordingly, the inventor has developed improved systems andmethods for controlling the flow of fluids through discharge outlets.

SUMMARY OF THE INVENTION

[0005] In one aspect, the present invention is directed towards aflapper configured to seal a tank discharge opening. The flapperincludes a first seal member movable between a first seal open positionand a first seal closed position. The first seal member is configured torestrict the flow of fluid through a first portion of the dischargeopening when the first seal member is in the first seal closed position.The flapper also includes a second seal member movable between a secondseal open position and a second seal closed position, and wherein thesecond seal member is configured to restrict the flow of water through asecond portion of the discharge opening when the second seal member isin the second seal closed position.

[0006] In another aspect, the present invention is directed towards aflapper assembly moveable between an open position, at least oneintermediate position and a closed position. In the open position fluidis able to flow substantially unrestricted by the flapper assemblythrough a discharge outlet. In the at least one intermediate position,fluid is partially restricted, but not prevented, from flowing throughthe discharge outlet. In the closed position fluid is prevented fromflowing through the discharge outlet.

[0007] In yet another aspect the present invention is directed towards amethod of controlling a flow of water through a toilet tank dischargeoutlet The steps of the method include:

[0008] (a) permitting water to flow substantially unrestricted throughthe discharge outlet for a first period of time;

[0009] (b) partially restricting the flow of fluid through the dischargeoutlet for a second period of time; and

[0010] (c) sealing the discharge outlet thereby preventing the flow offluid through the discharge outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present invention will now be described, by way of exampleonly, with reference to the following drawings, in which like referencenumerals refer to like parts and in which:

[0012]FIG. 1 is a top perspective view of a flapper assembly made inaccordance with the present invention;

[0013]FIG. 2 is a top perspective view of the flapper assembly of FIG.1, mounted within a toilet tank and in a fully closed position;

[0014]FIG. 3 is a top perspective view of the flapper assembly of FIG.1, mounted within a toilet tank and in a fully open position; and

[0015]FIG. 4 is a top perspective view of the flapper assembly of FIG.1, mounted within a toilet tank and in an intermediate position.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to FIG. 1, illustrated therein is a flapper assembly,referred to generally as 10, made in accordance with the presentinvention. The flapper 10 comprises a first seal member 12 and a secondseal member 14. The second seal member 14 is pivotally coupled to thefirst seal member 12, typically by a hinge joint 16. The second sealmember 14 preferably comprises an internal chamber 15. The internalchamber 15 is closed but has a chamber aperture 17 at a lower portionthereof. As will be understood, when the chamber 15 is filled with air,the air trapped in the chamber 15 provides buoyancy to the second sealmember 14. Preferably, the first and second seal members 12, 14 areformed of rubber, silicon or other durable material capable of forming awatertight seal.

[0017] The first seal member 12 also comprises a first hinge mount 18,typically in the form of “ears”, and configured to pivotally engage asecond hinge mount. As illustrated in FIG. 2, in toilet tanks, typicallythe second hinge mount 20 is in the form of pins located at the base ofa flush valve assembly 22 mounted to the toilet tank 24.

[0018] The first seal member 12 is also provided with a ring 26 or otherconnection mount for attaching a chain 28 or similar connector mechanismwhich in turn is coupled to a toilet flush lever. The chain 28 may alsobe provided with a float 29.

[0019] As can be seen in FIG. 3, the flapper assembly 10, and inparticular the first seal member 12 is designed to seat against thedischarge outlet 30 at the bottom of the toilet tank 24, when the firstseal member 12 (and the flapper assembly 10) is in the closed positionshown in FIG. 2. As will be understood, the discharge outlet 30 has adischarge opening 32 through which water or other fluid stored in thetank 24 may flow.

[0020] As can be seen in FIG. 4, the first seal member 12 has anaperture or passageway 34, which is smaller in size than the dischargeopening 32. The second seal member 14 is configured to form a watertightseal of the aperture 34 when the second seal member 14 is seated againstthe first seal member 12. The second seal member 14 preferably seats onthe upper surface of the first seal member 12, rather than against theinner edges of the aperture 34, in order to facilitate freedom ofmovement between the first seal member 12 and second seal member 14.

[0021] Referring again to FIG. 2, in use the flapper assembly 10 istypically in its closed position sealing the discharge outlet 30 andpreventing water or other fluid stored in the tank 24 from flowingthrough the outlet 30. When the toilet is to be flushed the flush handleis typically depressed, raising the flush lever and the attached chain28, and thereby raising the flapper assembly 10 to an open position asillustrated in FIG. 3. When the assembly 10 is in the open position, thefluid stored in the tank 24 Is able to flow substantially unrestrictedthrough the entire discharge opening 32.

[0022] When the toilet flush lever has been released and after a firstvolume of water has exited the tank 24 through the discharge outlet 30,the assembly 10 moves to its intermediate position in which the firstseal member 12 is in the first seal closed position and the second sealmember 14 is in the second seal open position, shown in FIG. 4. Theassembly 10 pivots downwardly toward the discharge outlet 34. Under theeffect of gravity, movement downward through the waer is resisited bythe drag of the assembly moving through the water. Because the secondseal member 14 is freely pivotally connected to the first seal member12, the drag force acting on the second seal member 14 acts to raise itrelative to the first seal member 12. In addition, the buoyancy providedby the air-filled internal chamber 15 facilitates the separation of thesecond seal member 14 from the first seal member 12.

[0023] In this position, fluid may flow through the aperture 34 andthrough the discharge opening 32. However, as will be understood, thisflow rate is reduced in comparison to the flow rate when the apparatus10 is in the open position. Since the aperture 34 is smaller in sizethan the opening 32. the fluid is restricted from flowing through afirst portion of the discharge opening 32 which is covered by the firstseal member 12 Fluid is permitted to flow through a second portion ofthe discharge opening 32, which coincides with the area defined by theaperture 34.

[0024] As the second seal member 14 moves to or reaches the second sealopen position, some air may be released through the chamber aperture 17and water may flow into the chamber 15, thereby reducing the buoyancy ofthe second seal member 14 and increasing its effective weight. After asecond volume of water has flowed through the aperture 34 at a reducedrate, the second seal member 14 descends to the second seal closedposition, with the apparatus 10 in the dosed position illustrated inFIG. 2 In this position, the second seal member 14 restricts, and in theillustrated embodiment, prevents fluid flowing through the secondportion of the discharge opening 32, defined by the aperture 34. In thisclosed position, the apparatus 10 seals the discharge outlet 30, and thetank 24 may then be refilled with water or other fluid. As well, anywater which has entered the internal chamber 15 is able to drain fromthe chamber aperture 17 through the discharge outlet 30, and followingcompletion of the flushing process, air is able to enter the chamber 15from the toilet bowl via the discharge outlet 30.

[0025] As will be understood, the first and second seal members 12, 14are preferably configured such that the total volume of water flowingthrough the discharge outlet 30 during the flushing process describedabove, may be reduced from the volume of water flushing through adischarge outlet when using a standard single-piece prior an flapperassembly.

[0026] Additionally, the varying flow rates provided by theconfiguration of the flapper assembly 10 may provide improved flushingaction over flushing an equivalent volume of water using a standardsingle-piece prior art flapper assembly. The flapper assembly 10 reducesthe average flow rate (as compared to a standard single-piece flapper)because of the reduced effective discharge outlet size (when theassembly is in its intermediate position shown in FIG. 4) and therebylengthens the time to drain a set volume of water through the dischargeoutlet 30. The flapper assembly 10 provides a large rush of water at thestart of the flush, when the assembly 10 is moved to the open positionillustrated in FIG. 3. After the initial surge of water is releasedthrough the discharge outlet 30, water is permitted to flow through theaperture 34 at a reduced rate when the assembly 10 is in theintermediate position illustrated in FIG. 4. This preferably enablesenhanced siphoning of the toilet system.

[0027] As illustrated in FIG. 4, preferably the hinge joint 16 pivotallycoupling the first 12 and second 14 seal members is positioned on theopposite side of the aperture 34 from the first hinge mount 18. Theposition of the hinge joint 16 forms an angle of approximately 180°through the center point of the aperture 34 and a mid-point of the firsthinge mount 18. The hinge 16 may otherwise be positioned proximate theaperture 34, forming different angles through the center of the aperture34 and the first hinge mount 18, but it is believed that the relativepositioning of the hinges 16, 18 & 20 illustrated in the Figures worksmost effectively.

[0028] As well, with the chain 28 positioned to the rear of the hingejoint 16, the second seal member 14 is prevented from pivoting to andpast the vertical as the first seal member 12 pivots down from the firstseal open position to the first seal closed position. Such a constraintensures that gravity is ultimately able to pivot the second seal member14 to the second seal closed position illustrated in FIG. 2. Alternatemeans may be provided to constrain the second seal member 14 frompivoting to and past a vertical alignment.

[0029] Preferably the first hinge mount 18 and the individual componentsin the assembly 10 (and the first seal member 12, in particular) will besized and configured to fit existing toilet tank 24 configurations, tofacilitate replacement of old flappers with the flapper assembly 10 ofthe present invention, as will be understood.

[0030] Additionally, while the Figures illustrate a hinge joint 16having “ears” and pins, between the first 12 and second 14 seal members,other methods of positioning the second seal member 14 relative to thefirst 12 may be used. For example, a pivot may be formed of flexiblematerial connecting the first 12 and second 14 seal members together.

[0031] The second seal member 14 has been described as having aninternal chamber 15 having a chamber aperture 17. The chamber aperture17 allows for the exchange of air and water into the chamber 15, whichadjusts the buoyancy and effective weight of the second seal member 14and facilitates the descent of the second seal from the second seal openposition to the second seal closed position. As will be understoodadjustments can be made to the size and configuration of the chamber 15and the size of the chamber aperture 17, thereby varying the buoyancy(and rate of change of buoyancy) and hence the rate of descent of thesecond seal member 14. Similarly, more than one chamber aperture 17 maybe provided.

[0032] Additionally, while the chamber 15 has been described as having achamber aperture 17, in alternative embodiments, the chamber 15 may nothave a chamber aperture 17. In such instance, if the buoyancy providedby the chamber 15 is sufficiently high, the second seal member 14 maynot be able to descend to the second seal closed position until thewater level in the tank toilet tank is near the bottom of the tank. Toachieve water conservation with such an embodiment, it may provenecessary to reduce the amount of water stored in the tank for exampleby adjusting the toilet tank float valve, or by putting bricks in thetank, or through other means.

[0033] Furthermore, in place of a chamber 15, alternate means (such asmanufacturing the second seal member 14 out of sufficiently buoyantmaterial) may be utilized for providing buoyancy to the second sealmember 15, for the purpose of facilitating a sufficiently slow descentfrom the second seal open position to the second seal closed positionand provide a sufficiently long flush period.

[0034] Thus, while what is shown and described herein constitutespreferred embodiments of the subject invention, it should be understoodthat various changes can be made without departing from the subjectinvention, the scope of which is defined in the appended claims.

1. A flapper configured to seal a tank discharge opening, the flappercomprising: (a) a first seal member movable between a first seal openposition and a first seal closed position, and wherein the first sealmember is configured to restrict the flow of fluid through a firstportion of the discharge opening when the first seal member is in thefirst seal closed position; and (b) a second seal member movable betweena second seal open position and a second seal closed position, andwherein the second seal member is configured to restrict the flow ofwater through a second portion of the discharge opening when the secondseal member is in the second seal closed position.
 2. A flapper asclaimed in claim 1, wherein the first seal member and the second sealmember seal the discharge opening when the first seal is in the firstseal closed position and the second seal member is in the second sealclosed position.
 3. A flapper as claimed in claim 1, further comprisinga first hinge mount configured to pivotally engage a second hinge mount,wherein the second hinge mount is operatively coupled to the toilettank.
 4. A flapper as claimed in claim 1, wherein the first seal membercomprises an aperture through the first seal member, and wherein thesecond seal member is configured to seal the aperture when the firstseal member is in the first seal closed position and the second sealmember is in the second seal closed position.
 5. A flapper as claimed inclaim 1, wherein the second seal member is pivotally coupled to thefirst seal member.
 6. A flapper as claimed in claim 5, comprising ahinge for pivotally coupling the second seal member to the first sealmember.
 7. A flapper as claimed in claim 1 wherein the first seal memberdefines an aperture smaller then the discharge opening and wherein thesecond seal member is configured to prevent the flow of fluid throughthe aperture when the second seal member is in the second seal closedposition.
 8. A flapper as claimed in claim 1, further comprising aconnector for operatively coupling the toilet flapper to a flush lever.9. A flapper as claimed in claim 8, further comprising a float attachedto the connector.
 10. A flapper as claimed in claim 9, wherein theconnector comprises a chain.
 11. A flapper as claimed in claim 1,coupled to a flush lever.
 12. A flapper assembly moveable between anopen position, at least one intermediate position and a closed position;(a) wherein in the open position fluid is able to flow substantiallyunrestricted by the flapper assembly through a discharge outlet: (b)wherein in the at least one intermediate position fluid is partiallyrestricted but not prevented, from flowing through the discharge outlet;and (c) wherein in the closed position fluid is prevented from flowingthrough the discharge outlet.
 13. A flapper assembly as claimed in claim12, comprising: (a) a first seal member moveable between a first sealopen position and a first seal closed position, and wherein the firstseal member is configured to seat against the discharge outlet when thefirst seal member is in the first seal closed position; (b) wherein thefirst seal member defines an aperture smaller than the discharge outlet;and (c) a second seal member movable between a second seal open positionand a second seal closed position, and wherein the second seal member isconfigured to prevent the flow of fluid through the aperture when thesecond seal member is in the second seal closed position.
 14. A methodof controlling a flow of water through a toilet tank discharge outlet,the steps of the method comprising: (a) permitting water to flowsubstantially unrestricted through the discharge outlet for a firstperiod of time; (b) partially restricting the flow of fluid through thedischarge outlet for a second period of time, and (c) sealing thedischarge outlet thereby preventing the flow of fluid through thedischarge outlet.
 15. A flapper configured to seal a tank dischargeopening in a tank having only one flush lever, the flapper comprising:(a) a first seal member movable between a first seal open position and afirst seal closed position, and wherein the first seal member defines anaperture through the first seal member; (b) a second seal member freelypivotally coupled to the first seal member and movable between a secondseal open position and a second seal closed position, and wherein thesecond seal member is configured to seal the aperture when the secondseal member Is in the second seal closed position; and (c) wherein theflapper is provided with only one connector for coupling the flapper tosaid only one flush lever, wherein the connector is attached to thefirst seal member.
 16. The flapper as claimed in claim 15, coupled tosaid only one flush lever.